Method of manufacturing a wool pile fabric product

ABSTRACT

A method of manufacturing a component for an article of footwear including providing a two-part mold, inserting a first material layer in the mold, pouring a polyurethane layer on the first material layer, placing a piece of a wool pile fabric on the polyurethane layer and closing the mold for a designated period of time for forming a wool pile fabric component such as a footwear insole. After the designated period of time the mold is opened and the molded wool pile fabric component is removed from the mold.

PRIORITY CLAIM

The present non-provisional application claims priority to and the benefit of U.S. Provisional Application No. 61/618,470 filed on Mar. 30, 2012, U.S. Provisional Application No. 61/651,922 filed on May 25, 2012, U.S. Provisional Application No. 61/680,608 filed on Aug. 7, 2012 and U.S. Provisional Application No. 61/722,994 filed on Nov. 6, 2012, each of which are hereby incorporated by reference in their entireties.

BACKGROUND

Shearling is used in a variety of products including footwear, outwear, e.g., coats, gloves and hats, rugs, throws, pillows and car seat covers. It is an excellent insulator and yet breathes naturally. Natural wool fleece is soft, wicks moisture and provides for air circulation.

The cost associated with natural sheepskin products depends on the quality and the availability of sheepskin. Sheepskin quality varies considerably depending on many factors, including environmental factors. Accordingly, sheepskin is graded based on whether the sheepskin is a higher quality, i.e., little to no imperfections in the leather, or a lower quality, i.e., having many imperfections. Shearling quality and price is also impacted by the types of sheep that the shearling comes from. Certain types of sheep are more desirable because they produce better quality skins and/or softer fleece. Also, the number of the quality sheepskins available to manufacture the above products is limited by the number of sheep that are available. As demand for shearling and natural fleece products grows, the cost associated therewith also grows.

Accordingly, there is a need for products made from an alternative to shearling that replicates the desirable qualities of sheepskin while reducing the associated material costs.

BRIEF SUMMARY

The present invention provides a method or process of making a footwear component utilizing a sheared wool fabric. More specifically, sheared wool is knitted with a scrim material to form a natural wool, deep pile fabric that closely approximates sheepskin fleece and can be used in lieu of sheepskin in many applications including footwear components. The footwear component may be an insole, a liner or other component. The present method may also be used to manufacture liners and other components for apparel such as coats, gloves, hats, and other apparel products.

An embodiment of the present method of manufacturing a component part of an article of footwear includes providing a two-part mold, inserting a first material layer in the mold, pouring a polyurethane layer on the first material layer, placing a piece of a wool pile fabric on the polyurethane layer and closing the mold for a designated period of time for forming a wool pile fabric component such as a footwear insole. After the designated period of time the mold is opened and the molded wool pile fabric component is removed from the mold.

Another embodiment of the present method includes providing a two-part mold, inserting a wool pile fabric piece having a wool fiber side and a scrim side in the mold, pouring a liquid foam on the scrim side of the wool pile fabric piece and closing the mold for a designated period of time for forming a wool pile fabric component. After the designated period of time the mold is opened and the molded wool pile fabric component is removed from the mold.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a lower part of a two-part mold for forming an footwear insole where a first material is inserted in the lower part.

FIG. 2 is a perspective view of a lower part of a two-part mold of FIG. 1 where a second material is inserted in the lower part.

FIG. 3 is a perspective view of the two-part mold forming an embodiment of a footwear insole where the mold is in an open position.

FIG. 4 is a perspective view of the two-part mold of FIG. 3 where the mold is in a closed position.

FIG. 5 is a perspective view of an embodiment of the present footwear insole.

FIG. 6 is a perspective view of another embodiment of the present footwear insole.

FIG. 7 is a perspective view of the two-part mold forming another embodiment of a footwear insole where the mold is in an open position.

FIG. 8 is a perspective view of the two-part mold of FIG. 7 where the mold is in a closed position.

DETAILED DESCRIPTION

Various embodiments of the invention are described below by way of example only, with reference to the accompanying drawings. The drawings include schematic figures that may not be to scale, which will be fully understood by skilled artisans with reference to the accompanying description. Features may be exaggerated for purposes of illustration. From the preferred embodiments, artisans will recognize additional features and broader aspects of the invention.

The present disclosure is related to a method of manufacturing a wool pile fabric described in commonly owned U.S. patent application Ser. No. 13/838,551, entitled “Natural Wool Pile Fabric and Method for Making Wool Pile Fabric,” filed on Mar. 15, 2013, which is incorporated herein by reference.

FIG. 1 shows a lower part 12 of a two-part mold 10 (FIG. 3) used to make a footwear component, and more specifically, a footwear insole 14 for a shoe, boot or other footwear product. The two-part mold 10 may be any suitable mold. In FIG. 1, the lower part 12 of the mold 10 includes a recess 16 formed in the shape of the insole 14 where the insole may be for a right or left shoe. Initially, a piece of polyurethane laminated foam 18 is cut to the approximate shape of the recess 16 and placed in the recess in the bottom or lower mold part 12. The laminated foam 18 may be an Ortholite open-cell polyurethane foam, a memory foam or another suitable foam or foam product.

FIG. 2 shows the laminated foam 18 in the recess 16 of the lower part 12 of the mold 10 where a layer of polyurethane 20 is poured or otherwise applied to an upper surface 22 of the foam 18 and spread evenly over that surface. Preferably, the polyurethane layer 20 has a thickness of about two millimeters but may be of another suitable thickness. After the polyurethane is poured onto the laminated foam piece 18, the polyurethane layer 20 is allowed to cure for a designated period of time, and preferably until a dry film or “dry skin” appears on at least the upper surface 23 of the polyurethane layer.

In FIGS. 3-4, a piece of the sheared wool fabric 24 is cut to the approximate size of the insole 14 and placed onto the polyurethane layer 20. After the sheared wool product 24 is placed on the polyurethane layer, a top or upper part 13 of the mold 10 is pressed onto the lower part 12 of the mold to close the mold and press or mold the laminated foam 18, polyurethane layer 20 and sheared wool product 24 together. After a designated period of time, the mold 10 is opened, i.e., the lower and upper parts 12, 13 of the mold are separated, and the molded insole 14 is removed from the two-part mold. In the illustrated embodiment, the mold 10 is closed for approximately five minutes and then opened to remove the insole 14. It should be appreciated that the mold 10 may be closed for other time periods as maybe necessary to bond the components.

FIG. 5 shows the footwear insole 14 made by the above method where the insole includes the foam layer 18, the polyurethane layer 20 and the sheared wool pile fabric 24. In one embodiment, the laminated foam layer 18 and the polyurethane layer 20 are yellow and red respectively, but may be any suitable color or combination of colors. Similarly, the sheared wool product 24 is a white or cream color but may be dyed to any desired color or combination of colors. It should also be appreciated that the foam layer 18 and polyurethane layer 20 may be any suitable thickness.

FIG. 6 shows another footwear insole 26 having a different foam layer 28, a polyurethane layer 30 and sheared wool fabric layer 32. In this embodiment, a thicker foam is used for the foam layer where the foam may be the same foam described above or a different foam or combination of foams. It should be appreciated that other suitable foam, such as a laminated foam, may be used in the making of the footwear or apparel component.

FIGS. 7 and 8 show another embodiment of the footwear component manufacturing process. In this embodiment, a two-part mold 10′ having a lower part 12′ and an upper part 13′ is opened and a piece of the sheared wool pile fabric 31 is cut to the approximate size and shape of the insole (or other footwear component) and placed in the lower part with the wool pile side facing down or towards the bottom of recess 33. The scrim or backing material side 35 of the sheared wool product piece is facing up or toward the top part 13′ of the mold 10′. Next, a foam/cushioning material 37, in a liquid or semi-liquid state, is poured or otherwise applied to the scrim side 35 of the piece of sheared wool product. The liquid foam material 37 at least partially penetrates the backing material and into the wool fibers to create a bond between the foam material or foam material layer 37 and the sheared wool product 31. Preferably, the foam material 37 is applied to the sheared wool product 31 so that it penetrates the scrim and passes into and bonds with about 0.5 mm to 1 mm of fibers on the fiber side. Applying the liquid foam material in this manner, helps to make the wool fibers stand straighter (instead of laying or matting down in the same direction) to more closely replicate natural sheepskin where the fibers grow in many different directions. Any excess foam material that extends beyond the perimeter of the insole or footwear component can be trimmed.

In the above embodiments, the footwear component is made using a two-part mold 10 or 10′. It should be appreciated that a three-part mold or other suitable molds, such as a press mold or an injection mold, may be used to manufacture the component.

While particular embodiments of the present method have been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects. 

What is claimed is:
 1. A method of manufacturing a component for an article of footwear comprising: providing a two-part mold; inserting a first layer of a cushioning material in the mold; pouring a polyurethane layer on the first material layer; placing a piece of a wool pile fabric on the polyurethane layer; closing the mold for a designated period of time for forming a wool pile fabric component; and opening the mold and removing the molded wool pile fabric component after the designated period of time.
 2. The method of claim 1, wherein the cushioning material is a laminated foam.
 3. The method of claim 2, wherein the laminated foam is one of an open-cell polyurethane foam and a memory foam.
 4. The method of claim 1, wherein the cushioning material layer is a piece of polyurethane laminated foam.
 5. The method of claim 1, wherein the polyurethane layer has a thickness of 2 mm.
 6. The method of claim 1, wherein the wool pile fabric component is a footwear insole.
 7. A method of manufacturing a component for an article of footwear comprising: providing a two-part mold; inserting a wool pile fabric piece having a wool fiber side and a scrim side in the mold; pouring a liquid foam on the scrim side of the wool pile fabric piece; and closing the mold for a designated period of time for forming a wool pile fabric component; and opening the mold and removing the molded wool pile fabric component after the designated period of time.
 8. The method of claim 7, wherein the liquid foam is one of an open-cell polyurethane foam and a memory foam.
 9. The method of claim 7, further comprising waiting a designated period of time after pouring the liquid foam on the scrim side of the wool pile fabric and prior to closing the mold to allow the liquid foam to penetrate through the scrim and engage at least a portion of the wool fibers.
 10. The method of claim 9, wherein the liquid foam bonds with 0.5 to 1.0 mm of a length of the wool fibers.
 11. The method of claim 7, wherein the wool pile fabric component is a footwear insole. 